Panel joining arrangement for a vehicle canopy

ABSTRACT

The disclosure relates to a panel joining arrangement for a vehicle canopy. The vehicle canopy includes at least one three panel join where a side panel, roof panel and end panel of the vehicle canopy meet. The panel joining arrangement comprises first and second lip portions formed in the side panel of the vehicle canopy and a third lip portion formed in the roof panel. The first and second lip portions are longitudinally offset and transversely overlapping in relation to a length of the side panel. The third lip portion is configured to mate with the second lip portion at the three panel join of the vehicle canopy such that the third lip portion is located adjacent to and substantially flush with the first lip portion.

FIELD OF THE INVENTION

The invention relates, generally, to vehicle canopies and to kits forassembling vehicle canopies. More specifically, the invention relates toa panel joining arrangement for such a kit or vehicle canopy.

BACKGROUND TO THE INVENTION

For purposes of interpreting this specification, the term “canopy” or“vehicle canopy” refers to a cover for a load bin of a vehicle such as a“bakkie”, as they are generally known in South Africa, or a utilityvehicle or pick-up truck, as they are generally known elsewhere in theworld.

The Applicant previously developed a flat pack kit for a canopy. The kitincludes a roof panel, side panels and one or more end panels (e.g. afront panel and a rear panel). The panels are specifically shaped,dimensioned and configured to be flat packed and assembled and the kitcan thus be distributed as a complete knock-down (CKD). The basicconcept of the kit is described in Patent Cooperation Treaty (PCT)Patent Application No. PCT/IB2015/057124, published as WO/2016/024494 on24 Mar. 2016, which is incorporated by reference herein.

The Applicant's kit has been commercially successful. The Applicantbelieves that the success of the kit can be attributed at least in partto its knock-down construction and robust features. A number ofdifferent ranges, variations and modifications have been introduced overthe years to expand on and enhance the Applicant's product offering.

However, designing a CKD which, when assembled and installed,satisfactorily seals off the interior of the canopy has remained achallenge. Small spaces or gaps between adjacent parts of the assembledcanopy allow for the passage of water, dust and/or other unwantedparticles into the interior of the canopy.

Referring specifically to water leaks, the Applicant has found that thecorner zones where the roof panel meets with respective side andend/junction panels are prone to water leakage. In the context of thisspecification, the term “three panel corner join” or simply “three paneljoin” is used to refer to the zone where a roof panel meets with a sideand end panel (or other similar panel). The canopy typically includes aroof panel, two opposing side panels, a front panel and a rear panel, inwhich case the canopy therefore defines four three panel joins.

By way of example, FIGS. 1 to 4 illustrate gaps formed at the threepanel joins of two of the Applicant's known canopies.

FIGS. 1 and 2 show a gap 102 in a first canopy. The first canopy isshown in a partially assembled condition, with a roof panel 104 in theprocess of being connected to a side panel 106. The gap 102 is formed asa result of the roof panel 104 not abutting the side panel 106 at thethree panel join 116. More specifically, an outer surface 108 of a lip110 of the roof panel 104 is not adjacent to and flush with an outersurface 112 of a lip 114 of the side panel 106 (no end panel is shown inFIGS. 1 and 2 to illustrate the gap 102 more clearly).

FIGS. 3 and 4 show a gap 118 at a three panel join of a second canopywhich is in an assembled condition, with a roof panel 120 connected to aside panel 122 and an end panel 126. FIG. 3 illustrates the canopy fromthe inside while FIG. 4 illustrates the canopy from the outside. The gap118 is formed as a result of the design as explained with reference toFIGS. 1 and 2 above. It will be appreciated that the gaps 102 and 118may allow water to enter the canopy.

In an attempt to address this issue, sealant, e.g. silicone sealant, canbe applied at the three panel joins after assembly of the vehiclecanopy. However, this is undesirable as the kit is preferably providedto a customer in flat pack form and it may be difficult for and/orundesirable to have a customer carry out the sealing step. If thesealant is not applied properly, gaps will still be present at the threepanel joins, resulting in possible leaks. Furthermore, this additionalstep adds to the cost associated with the product and unwanted time isspent on sealing the canopy.

The present invention aims to address or alleviate the issue describedabove, at least to some extent.

SUMMARY OF THE INVENTION

In accordance with a first aspect of the invention, there is provided apanel joining arrangement for a vehicle canopy, the canopy including atleast one three panel join, wherein the panel joining arrangementcomprises first and second lip portions formed in a side panel of thecanopy, the first and second lip portions being longitudinally offsetand transversely overlapping in relation to a length of the side panel,the panel joining arrangement further comprising a third lip portionformed in a roof panel of the canopy, wherein the third lip portion isconfigured to mate with the second lip portion at the three panel joinof the canopy such that the third lip portion is located adjacent to andsubstantially flush with the first lip portion.

The third lip portion may be located in abutment with the first lipportion.

The arrangement may be configured such that, in an assembled conditionof the canopy, an outer surface of the first lip portion issubstantially flush with and laterally adjacent to an outer surface ofthe third lip portion. The arrangement may further be configured suchthat, in the assembled condition, an outer surface of the second lipportion, or at least a substantial part thereof, directly faces an innersurface of the third lip portion.

The arrangement may further include a sealing material which, in theassembled condition, is located between the outer surface of the secondlip portion and the inner surface of the third lip portion. The sealingmaterial may be sealing foam tape applied to an interior of the roofpanel.

The arrangement may further include a fourth lip portion formed in anend panel of the canopy and configured to mate with at least the thirdlip portion at the three panel join. The fourth lip portion preferablyalso mates with the first lip portion adjacent to the three panel join.The end panel is preferably a front panel or a rear panel of the canopy.

The lip portions referred to above may be formed by or may form part ofbends in the side panel, roof panel or end panel of the canopy, as thecase may be. The bends may be 90 degree bends or near 90 degree bends.

In some embodiment, the third lip portion is defined by a return bend ofthe roof panel.

The first lip portion may be located at an end of the side panel and thesecond lip portion may located inwardly (e.g. slightly inwardly relativeto the first lip portion) along the length of the side panel, thereby todefine a space for receiving the third lip portion in the assembledcondition of the vehicle canopy.

In accordance with a second aspect of the invention, there is provided akit for a canopy to be fitted to a vehicle, the kit including a paneljoining arrangement as described above. The kit may be a CKD.

In accordance with a third aspect of the invention, there is provided avehicle canopy which includes at least a side panel and a roof panelengaging with an end panel at a three panel join of the canopy, whereinfirst and second lip portions are formed in the side panel, the firstand second lip portions being longitudinally offset and transverselyoverlapping in relation to a length of the canopy, wherein a third lipportion is formed in the roof panel, the third lip portion mating withthe second lip portion at the three panel join such that the third lipportion is located adjacent to and substantially flush with the firstlip portion.

As mentioned above, a fourth lip portion may be formed in the end paneland may mate with at least the third lip portion at the three paneljoin.

In accordance with a fourth aspect of the invention, there is provided avehicle canopy including four three panel joins and a panel joiningarrangement substantially as described above associated with each of thethree panel joins.

The canopy may be fitted to any suitable vehicle, such as a motorvehicle (e.g. a bakkie), a caravan and/or a trailer.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be further described, by way of example, withreference to the accompanying drawings.

In the drawings:

FIG. 1 is a three-dimensional view of an example of a gap formed at athree panel join of a known vehicle canopy;

FIG. 2 is another three-dimensional view of the gap formed at the threepanel join of the vehicle canopy of FIG. 1;

FIG. 3 is a three-dimensional view illustrating an example of a gapformed at a three panel join of another known vehicle canopy;

FIG. 4 is another three-dimensional view illustrating the gap formed atthe three panel join of the vehicle canopy of FIG. 3;

FIG. 5 is a three-dimensional view of an embodiment of a side panel fora canopy, shown in an upside down orientation and showing aninterior/inside of the side panel, wherein the side panel includes partsof a panel joining arrangement according to the invention;

FIG. 6 is an enlarged view of zone “B” in FIG. 5;

FIG. 7 is a three-dimensional, partially exploded view of an embodimentof a roof panel for a canopy, showing an interior/inside of the roofpanel, wherein the roof panel includes part of a panel joiningarrangement according to the invention;

FIG. 8 is an enlarged view of zone “A” in FIG. 7;

FIGS. 9 and 10 are three-dimensional views illustrating a prototype of aside panel with lip portions according an embodiment of to theinvention;

FIGS. 11 to 13 are three-dimensional views of an embodiment illustratingthe manner in which side and roof panels can be joined according to theinvention;

FIGS. 14 to 16 are three-dimensional views of an embodiment illustratingthe manner in which side, roof and end panels can be joined according tothe invention;

FIGS. 17 and 18 are three-dimensional views illustrating aninterior/inside and an exterior/outside of an example of a canopy whichincludes a panel joining arrangement according to the invention;

FIG. 19 is a three-dimensional exploded view of a side panel, a roofpanel and an end panel of a canopy including an embodiment of a paneljoining arrangement according to the invention;

FIG. 20 is an enlarged view of zone “C” in FIG. 19, including hiddendetail;

FIG. 21 is a three-dimensional view of the side panel, roof panel andend panel of FIG. 19 in an assembled condition; and

FIG. 22 is an enlarged view of zone “D” in FIG. 21.

DETAILED DESCRIPTION WITH REFERENCE TO THE DRAWINGS

The following description of the invention is provided as an enablingteaching of the invention, is illustrative of the principles of theinvention and is not intended to limit the scope of the invention. Itwill be understood that changes can be made to the embodiment/sdescribed and depicted, while still attaining beneficial results of thepresent invention. Furthermore, it will be understood that some benefitsof the present invention can be attained by selecting some of thefeatures of the present invention without utilising other features.Accordingly, those skilled in the art will recognise that modificationsand adaptations to the present invention are possible and can even bedesirable in certain circumstances, and are a part of the presentinvention.

FIGS. 5 to 8 illustrate an example embodiment of a panel joiningarrangement according to the invention. FIGS. 5 and 6 illustrate a sidepanel 130 and FIGS. 7 and 8 illustrate a roof panel 132.

It should be understood that the side panel 130 and roof panel 132 mayform part of a kit for a canopy for a vehicle, typically comprising afurther side panel, a front panel and a rear panel (and/or other panelssuch as a junction panel), shaped to be flat packed and assembled. Eachpanel includes a lip which is complementally shaped to engage the lip ofat least one other panel. To assemble the canopy, the lips of adjacentpanels are located in abutment and are then secured together. The kitmay include the necessary attachment means to attach various panels toeach other and to the vehicle (not shown, but for instance as describedin PCT/IB2015/057124, published as WO/2016/024494).

As described above, when assembled, the roof panel 132 will meet withrespective side panels and end panels at four “three panel joins” or“three panel corner joins”. Therefore, a three panel join will bedefined at each of the four operatively upper corners 131 of the roofpanel 132, as well as at two operatively upper corners 133 of the sidepanel 130.

The side panel 130 has a pair of first and second lip portions 134, 136at each end thereof, located in the corners 133 referred to above. Byway of example, the lip portions 134, 136 in the zone “B” in FIGS. 5 and6 will be described below.

The first lip portion 134 and the second lip portion 136 are separate 90degree bends at an end of the side panel 130. The lip portions 134, 136may be bent stainless steel portions. The lip portions 134 arelongitudinally offset and transversely overlapping. In other words, whenthe side panel 130 is viewed from the side, the lip portions 134, 136are slightly spaced apart, and when the side panel 130 is viewed fromthe end or in cross-section, the lip portions 134, 136 overlap. Theseaspects are also clearly shown in FIGS. 9 and 10, which illustrate aprototype of the side panel 138 which includes the offset andoverlapping first lip portion 140 and second lip portion 142.

Referring in greater detail to FIGS. 7 and 8, the roof panel 132 has acontinuous 90 degree bend at each end thereof (this may be referred toas the “return bend” of the roof panel 132), defining a third lipportion 144 at each of the corners 131 of the roof panel 132. A sealingmaterial in the form of sealing foam tape 146 is applied to the interiorof the roof panel 132, at opposite sides thereof, extending along thelength of the roof panel 132. The sealing foam tape 146 is shown in an“exploded” manner in FIGS. 7 and 8 to illustrate the components of theroof panel 132 more clearly. As is evident from FIG. 8 in particular,the sealing foam tape 146 has a bend 145 at each of its end regions,corresponding to the bend defining the third lip portion 144 forconforming to the shape of the third lip portion 144 when the canopy isassembled.

Each third lip portion 144 is configured to mate with a correspondingsecond lip portion 136 such that the third lip portion 144 is locatedadjacent to and substantially flush with a corresponding first lipportion 134. The design and advantages of this configuration will bedescribed in greater detail with reference to the examples in FIGS. 11to 18 below.

Referring to FIGS. 11 to 13, the side panel 138 mates with the roofpanel 150 by means of complementally shaped spigots 152 and sockets 154and the panels 138, 150 are secured to each other by suitable fasteners(not shown in FIGS. 11 to 13, but visible in FIG. 7). The spigots 152are located on a bent surface of the side panel 138. This bent surfaceis connected to the bend which forms the second lip portion 142 and thesecond lip portion 142 extends at a 90 degree angle relative to the bentsurface. The bent surface of the side panel 138 is positioned on acomplemental surface of the roof panel 150 and adjacent to anoperatively vertical section of the roof panel 150, which defines thesockets 154, when the spigots 152 are inserted into the sockets 154.

When in the mating condition (see FIGS. 12 and 13; FIG. 11 shows adisassembled condition), an outer surface 156 of the first lip portionis substantially flush with and laterally adjacent to an outer surface158 of the third lip portion 160 on the roof panel 150. Furthermore, anouter surface 162 of the second lip portion directly faces an innersurface 164 of the third lip portion 160. This design ensures that thegap in the three panel join area of the canopies, as described in the“Background” section above and shown in FIGS. 1 to 4, is substantiallyobviated.

FIGS. 14 and 15 also show a fourth lip portion 166 defined by a bend inthe end panel 168 (e.g. front or rear) which engages with the side panel138 and roof panel 150 at the three panel join. As is clear from FIG.15, the fourth lip portion 166 mates with both the first lip portion 140and the third lip portion 160 and is directly secured to the first lipportion 140 by a suitable fastener 180. In other words, a face of thefourth lip portion 166 faces the outer surfaces of the first lip portion140 and the third lip portion 160.

The Applicant has found that the first lip portion 140 and third lipportion 160 need not be exactly flush: at least a near flush arrangementin combination with the overlapping feature has been found to beeffective in reducing or preventing leaks. FIG. 16 shows an example ofthe three panel corner join 172 from the outside, i.e. the part of thecanopy that will be exposed to the elements in use.

FIG. 15 also shows the portion of the sealing foam tape 170 which islocated between the outer surface 162 of the second lip portion 142 andthe inner surface 164 of the third lip portion 160. This portioncorresponds to the bend in the sealing foam tape 146 described withreference to FIGS. 7 and 8.

By way of further example, FIGS. 17 and 18 show parts of the interiorand exterior, respectively, of an assembled vehicle canopy incorporatingthe panel joining arrangement described above at a three panel join 174.

Another embodiment of the panel joining arrangement is shown in FIGS. 19to 22. These Figures illustrate a side panel 230, a roof panel 232 andan end panel 268 (in this case the end panel 268 is a rear panel that ispositioned adjacent to or against a vehicle cab, in use).

It should be understood that the side panel 230, roof panel 232 and endpanel 268 may form part of a kit for a canopy for a vehicle, typicallycomprising a further side panel and a front panel (and/or other panelssuch as a junction panel), shaped to be flat packed and assembled. Eachpanel includes a lip which is complementally shaped to engage the lip ofat least one other panel. To assemble the canopy, the lips of adjacentpanels are located in abutment and are then secured together. The kitmay include the necessary attachment means to attach various panels toeach other and to the vehicle (not shown, but for instance as describedin PCT/IB2015/057124, published as WO/2016/024494).

As described above, when assembled, the roof panel 232 engages withrespective side panels and end panels at four “three panel joins”, oneof which is located in the zone “D” of FIGS. 21 and 22 and its locationis indicated by reference numeral 290. The arrangement at this specificzone is described below to illustrate certain aspects of the invention.

The side panel 230 has a pair of first and second lip portions 234, 236at each end thereof, located in the operatively upper corner zonesreferred to above. By way of example, the lip portions 234, 236 in thezone “C” in FIG. 20 will be described below.

The first lip portion 234 and the second lip portion 236 are separate 90degree bends at an end of the side panel 230. The lip portions 234, 236may be bent stainless steel portions. The lip portions 234 arelongitudinally offset and transversely overlapping. In other words, whenthe side panel 230 is viewed from the side, the lip portions 234, 236are slightly spaced apart, and when the side panel 230 is viewed fromthe end, the lip portions 234, 236 overlap, as is clear from the hiddendetail in FIG. 20. The first lip portion 234 is located at the end ofthe side panel 230 while the second lip portion 236 is spaced slightlyinwardly along the length of the side panel 230 to define a space forreceiving a third lip portion on the roof panel 232 as will be describedbelow.

The roof panel 232 has a continuous 90 degree bend at each end thereof(this may be referred to as the “return bend” of the roof panel 232),defining a third lip portion 244 at each of the four corners of the roofpanel 232. A sealing material may be applied to the interior of the roofpanel 232 as described with reference to FIGS. 7 and 8 above and itsshape may conform to that of the third lip portion 244 when the canopyis assembled. The sealing material may be located between the third lipportion 244 and the second lip portion 236 in the assembled condition.

Each third lip portion 244 is configured to mate with a correspondingsecond lip portion 236 such that the third lip portion 244 is locatedadjacent to and substantially flush with a corresponding first lipportion 234. In other words, when the canopy is assembled, the third lipportion 244 slides behind (i.e. over the outer face) of the second lipportion 236 and the third lip portion 244 becomes oriented substantiallyparallel to the first lip portion 234.

The side panel 230 and the roof panel 232 are connected by complementalmating formations and fasteners as already described above. When in themating/assembled condition, an outer surface of the first lip portion234 (the surface shown in FIG. 20) is substantially flush with andlaterally adjacent to an outer surface (the surface shown in FIG. 20) ofthe third lip portion 244 on the roof panel 232.

An outer surface of the second lip portion 236 (the surface shown inFIG. 20) directly faces an inner surface of the third lip portion 244 inthe assembled condition. This design ensures that the gap in the threepanel join area of the canopies, as described in the “Background”section above and shown in FIGS. 1 to 4, is substantially obviated,reducing or preventing leakage especially through the area 292 indicatedin FIG. 22.

A fourth lip portion 266 defined by a 90 degree bend in an upper regionof the end panel 268 which engages with the side panel 230 and roofpanel 232 at the three panel join. As is clear from FIG. 20, the fourthlip portion 266 is configured to mate with both the first lip portion234 and the third lip portion 244, e.g. the face of the end panel 268which defines the fourth lip portion 266 can be clipped to both thefirst lip portion 234 on the side panel 230 and the third lip portion266 on the roof panel 232 using suitable fasteners. The outer face ofthe fourth lip portion 266 then faces the outer surfaces of the firstlip portion 234 and the third lip portion 244 when the parts areassembled as shown in FIGS. 21 and 22.

The Applicant believes that the panel joining arrangement describedherein will prevent or at least reduce water leaks and possibly otherunwanted particle ingress at the three panel joins of CKD vehiclecanopies. Leaks may be prevented or reduced by the extension of the“return bend” on the roof panel up to the ends of the roof panel, and byproviding offset and overlapping bend lips on the side panel which matewith the roof panel. The end panels then mate snugly with the roof andside panels to define an enhanced three panel join.

The addition of sealing tape to this arrangement may assist in sealingalong the adjoining edge between the roof panel and side panelcomponents. This may obviate the need for a customer or end user toapply additional sealant. It may also reduce the costs associated withthe product and reduce time required to seal the canopy.

1. A panel joining arrangement for a vehicle canopy, the vehicle canopyincluding at least one three panel join, wherein the panel joiningarrangement comprises first and second lip portions formed in a sidepanel of the vehicle canopy, the first and second lip portions beinglongitudinally offset and transversely overlapping in relation to alength of the side panel, the panel joining arrangement furthercomprising a third lip portion formed in a roof panel of the vehiclecanopy, wherein the third lip portion is configured to mate with thesecond lip portion at the three panel join of the vehicle canopy suchthat the third lip portion is located adjacent to and substantiallyflush with the first lip portion.
 2. The panel joining arrangementaccording to claim 1 which is configured such that, in an assembledcondition of the vehicle canopy, an outer surface of the first lipportion is substantially flush with and laterally adjacent to an outersurface of the third lip portion.
 3. The panel joining arrangementaccording to claim 2 which is further configured such that, in theassembled condition of the vehicle canopy, an outer surface of thesecond lip portion, or at least a part thereof, directly faces an innersurface of the third lip portion.
 4. The panel joining arrangementaccording to claim 3 which further includes a sealing material which, inthe assembled condition, is located between the outer surface of thesecond lip portion and the inner surface of the third lip portion. 5.The panel joining arrangement according to claim 4, wherein the sealingmaterial is sealing foam tape applied to an interior of the roof panel.6. The panel joining arrangement according to claim 1 which furtherincludes a fourth lip portion formed in an end panel of the vehiclecanopy and configured to mate with at least the third lip portion at thethree panel join.
 7. The panel joining arrangement according to claim 6,wherein the fourth lip portion is configured also to mate with the firstlip portion.
 8. The panel joining arrangement according to claim 6,wherein the end panel defining the fourth lip portion is a front panelor a rear panel of the vehicle canopy.
 9. The panel joining arrangementaccording to claim 1, wherein the first, second and third lip portionsare formed by bends in the side panel and the roof panel.
 10. The paneljoining arrangement according to claim 9, wherein the bends are 90degree bends or near 90 degree bends.
 11. The panel joining arrangementaccording to claim 1, wherein the third lip portion is defined by areturn bend of the roof panel, wherein the first lip portion is locatedat an end of the side panel and the second lip portion is locatedinwardly along the length of the side panel, thereby to define a spacefor receiving the third lip portion in an assembled condition of thevehicle canopy.
 12. A kit for a vehicle canopy, the kit including apanel joining arrangement according to claim
 1. 13. A vehicle canopywhich includes four three panel joins and a panel joining arrangementaccording to claim 1 associated with each of the three panel joins. 14.A vehicle canopy which includes at least a side panel and a roof panelengaging with an end panel at a three panel join of the vehicle canopy,wherein first and second lip portions are formed in the side panel, thefirst and second lip portions being longitudinally offset andtransversely overlapping in relation to a length of the vehicle canopy,wherein a third lip portion is formed in the roof panel, the third lipportion mating with the second lip portion at the three panel join suchthat the third lip portion is located adjacent to and substantiallyflush with the first lip portion.
 15. The vehicle canopy according toclaim 14, wherein a fourth lip portion is formed in the end panel andmates with at least the third lip portion at the three panel join.